Method and machine for winding coils



May 11, 1948. R'. D. NELSON 2,441,439

METHOD AND MACHINE FOR WINDING COILS Filed Dec. 6, 1944 2 Sheets-Sheet 1INVENTOR. foam/o a 421mm 770 IVE)- May 11, 1948.

-R. p. NELSON IBTHOD AND IACHINE FOR WINDING COILS Filed Dec. 6, 1944 2Sheets-Sheet 2 INVENTOR. fowl/v0 A? #5130 Patented May 11, 1948 PATENTOFFICE 2,441,439 METHOD AND MACHINE FOR WINDING COILS Rolland D. Nelson,to Line Material Hales Corners, Wis., assignor Company, South Milwaukee,

Via, a corporation of Delaware Application December 6, 1944, Serial No.566,866

9 Claims. 1

This invention relates to a machine for winding coils and to a method ofwinding coils.

Objects of this invention are to provide a machine and a method forwinding conducting coils on a magnetic core for an electromagneticdevice such, for example, as a transformer, choke coil or the like, theinvention contemplating particularly the winding of a conducting coil ona closed magnetic core after the core has been completelyformed andannealed.

Further objects are winding a conducting coil on a closed magnetic core,the machine being so constructed that the coil may be wound directly ona shell surrounding a portion of the core, the shell being devoid of endflanges, the machine having means whereby the coil itself is directlyengaged by supporting and driving means for supporting the coil and forrotating the coil by direct contact with the outer portion of the coilas it is progressively formed.

In greater detail objects of this invention are to provide a windingmachine for winding a coil on a magnetic core, the winding machine beingprovided with a plurality of spaced rollers which directly engage andsupport the coil with the shell on which the coil is, wound held out ofcontact with the core and with one of the rollers acting as drivingmeans for rotating the coil, the

machine being so constructed that as the coil builds up, means areprovided for simultaneously moving each of the rollers outwardlyradially from the coil exactly the same amount to thus maintain theinitial position of the shell and yet compensating for the change insizeof the coil as it is bein wound.

A further object winding a conducting coil on a magneticicore whichmethod provides for the direct support of the coil by engagement withthe outer portion of the coil itself and which method provides aplurality of points of support at spaced positions around the coil soarranged that-the points of support simultaneously move radiallyoutwardly exactly the same amount as the coil builds up 7 duringwinding.-

to provide a machine for is to provide a winding ma'-' chine having theabove characteristics in which An embodiment of the invention is shownin the accompanying drawings in which:

Figure 1 is an end view of the machine. Figure 2 is a side elevation ofthe machine with a part of the transformer core in section and withparts of the machine broken away.

Figure 3 is a plan view parts broken away and parts in section.

Figure 4 is an enlarged sectional view on the line 4-4 of Figure 2.

Figure 5 is a view partly broken away and partly in section showing thefinished coil on the core.

Figure 6 is an-end view partly in section of a 16 different type ofshell from that shown in Figures 4 and 5.

Figure 7 is a side view at the shell shown in Figure 6,

Referring to the drawings, it will be seen that 20 the machine comprisesa main body portion consisting of a base portion I and an end frame 2integral with the base portion and projecting upwardly therefrom. Thebase of the machine is adapted to be mounted in any suitable manner notshown.

The end frame is provided with at least three. arms or portionsindicated by the reference character 3. These portions are provided withradially extending slots 4 which are guide slots adapted to receiveslide blocks or members 5. These slide blocks 5, as shown particularlyvin Figure 3, are provided with rearwardly positioned shouldered portions6 and with beveled faces I. Guide strips 8 are lremovably secured to therear faces ofthe-portions 3 of the front frame and have beveled facescoacting with the beveled faces I of the slide blocks or slides 5. Eachslide block 5 is rigidly attached to and carries as a unitary portionthereof an axle or shaft 9 which projects revolubly supports a rubberroller or other typ of yielding roller Ill such roller being preferablyprovided with an inner metal ferrule or bearing sleeve ll. Means areprovided for preventing axial shifting of the rollers In on the pins orshafts 9. As shown in Figure 3, the sleeves II are extended so thattheyengage the inner faces of the slide blocks 5 at their. inner ends.Their outer ends bear against washers I2 held in place by means of boltsl3.

It is to be noted from reference to Figure 4 that the lower pair ofrollers l0 are'positioned more closely with reference to each other thanwith reference to the uppermost roller Ill. The lower rollers act tosupport the weight of the coil of the machine with rearwardly from theguide block. Each shaft 9' and the upper roller serves to press the coildown into position against the lower rollers Ill. The sleeve H of one ofthe lower rollers I is provided with a v pulley II which is driven bymeans of a V belt l5 from the V pulley IQ of a variable speed electricmotor l'l, such motor pref ra ly h v speed reducing mechanism built in aportion thereof such as the portion l8 atits front end. The motor isadapted to be controlled by a rheostat or in any suitable manner forcontrolling its speed.

Each slide block 5 is rigidly attached to a rack I9. The racks arearranged at slightly different distances outwardly from the front frame2 of the machine so that they lie in overlapping relation to each other.The racks are each engaged by a wide faced pinion 20 which is rigidlymounted on a shaft 2| centrally mounted with reference to the rollersID. This shaft is provided with a manually operable crank or handle 22so that by rotation of the handle the rollers may be moved outwardly. Arelatively heavy coil spring 23 is positioned around the shaft 2!, seeFigure 3, and urges the shaft towards rotation in a direction to drawall of the rollers l9 radially inwardly as indicated-by the arrows inFigure 4. It is obvious that motion of any one roller radially inwardlyor outwardly is transmitted to the remaining rollers and that all therollers move simultaneously thesame amount either radially outwardly orinwardly.

The shaft 2| may be supported at its outer end by means of a spider 2dand may be supported at its inner end directly in the front frame 2 withthe master gear or tween the bearings. v

Any suitable means may be provided for supporting the closed magneticcore 25 of the transformer about a portion of which the conductingwinding assembly 26 is to be formed. For example, a cradle like frame 2?carried by suitable supports 23 may be provided and may be flanged toapproximately fit the contour of the core 23 of the transformer.

If desired, suitable clamping means could be employed for clamping themagnetic core in place such as shown, for instance, in the patent toSteinmayer et al., No. 2,305,999 of December 22, 1942, for Method andmachine for winding coils, or the patent to Schultz et al., No.

2,334,131 of November 9, 1943, for Machine for winding coils and methodof winding coils.

It is to be noted that the motor I! is not rigidly carried by the framebut is pivotally mounted as indicated at 32 in Figures 1 and 2. Thepurpose of this is to allow the motor to adjust itself as the rollersare shifted radially inwardly orv outwardly. The center of gravity ofthe motor is located to the side of the pivot 32 to maintain the belt i5tension. Obviously any other means could be employed.

A shell of insulating material is first positioned around that portionof the magnetic core on which the conducting winding is desired. In theform shown in Figure 3, for instance, it will be seen that theconducting winding is being formed around the central core of the shelltype transformer. The insulating shell may be formed of layers ofrelatively heavy paper or similar material glued together in positionaround the central portion of the magnetic core 25 and out of contacttherewith. Such shell is indicated by the reference character 29 inFigures 4 and 5. It is very much exaggerated in thickness in Figure 4for the sake of clearness.

pinion 23 located be v to Steinmayer et Obviously the insulating shellon which the conducting winding is formed may be made in other ways. Forinstance. it may be formed of two half sections 30 oi. plasticinsulating material and these two half sections together make a circularshell. They may be locked together in any way'as desired as by means ofthe insertable key pieces 3|, see Figure 7. Any other suitable type ofcylindrical shell could be employed. It is to be noted that no endflanges are needed as the rollers I 0 bear directly on the windingitself.

In using the machine, the-manually operable handle or crank 22 ismanipulated to open or move the rollers l0 radially outwardly. The coreand shell are then positioned and the rollers are released and moveinwardly under the influence of the spring 23. The winding 26 is startedaround the shell. Its end portions may be tied or any other portion maybe tied in any suitable manner as disclosed, for example, in the patenta1 hereinabove mentioned. The motor is operated at the appropriate speedand drives one of the lower rollers I!) as described above andconsequently rotates the shell and coil by direct engagement of theroller with the winding. Obviously any number of the rollers can be madedriving rollers if desired. It is, however, very much simpler to drive asingle roller as has been described hereinabove. It is clear that as thecoil builds up the supporting and driving means, namely the rollers itmove radially outwardly, progressively and at exactly the same rate timekeeping the coil centered with reference to the magnetic core andkeeping the shell out of contact with the core. This process continuesuntil the desired amount of wire has been wound to form a coil of therequisite number of turns.

Where the expression coil is referred to, it is intended that thisexpression be understood to cover any Winding assembly including theprimary and secondary of a transformer or a single coil of a choke orany other coil structure.

It is to be noted that the end turns or any portion of the winding maybe tied as hereinabove stated, the leads and the end portions havingbeen omitted for drawings.

means may be used for locking the coil in place.

For instance, wedges 33 formed of insulating material may be driven inplace between the magnetic core 25 and theshell 29 of the coil 26 asshown in Figure 5.

It will be seen that a very simple type of machine has been provided forwinding coils on magnetic cores, particularly on closed magnetic coresby directly engaging the winding itself. The necessity for end flangeson the insulating shell on which the winding is formed is avoided and avery simple type of shell can therefore be employed.

It will be seen further that the core and shell may be very readilyinitially positioned in the machine and also that the finished productcan be most readily removed from the machine.

the sake of clearness in the a coil on any type .01 core it isparticularly applicable to the winding of a coil on a closed mag? neticcore such as that formed of wound masnetic ribbon as shown in thedrawings.

Although this invention has been described in, considerable detail, itis to be understood that such description is intended as illustrativerather than limiting, as the invention may be variously embodied and isto be interpreted as claimed.

I claim:

1. The method of winding a conducting coll on a shell surrounding amagnetic core, said method comprising the steps of positioning a shellaround a part of said core and starting the coil around said shell,supporting said coil at spaced points by revoluble members directlyengaging said coil, rotating one of said members to rotate said coil andshell and winding a conducting winding on said shell, and simultaneouslyand progressively positively moving all oi! said revoluble membersradially outwardly the same amount while said winding builds up radiallyto thereby hold the shell out of contact with the core.

2. A machine for winding a coil on a magnetic core comprising means forrigidly supporting said core, a plurality oi spaced rollers arranged todirectly engage the winding at spaced points, means for driving one ofsaid rollers for causing uniform angular rotation of all portions ofsaid winding, and means positively mechanically connecting said rollersfor causing uniform and simultaneous radial motion of said rollersoutwardly from said core as said coil is progressively built up duringwinding.

3. A machine for winding a coil on a magnetic core comprising aplurality of spaced rollers arranged for rotary and translatory motion,means for imparting rotary motion to one of said rollers. meansoperatively connecting said rollers for causing simultaneous radialmotion of said rollers outwardly from said core as said coil is built upduring winding, and spring means for holding said rollers in directengagement with said coil.

6 rack means, a cominon pinion meshing with all of said rack means forcausing simultaneous motion. or said rollers inwardly or"'outwardly withreference to said core, power means for driving 'one or said rollers,and spring means acting on said pinion for urging saidrollers-inwardlytowards the coil whereby said rollers are normally spring held in directcontactwith said coil.

6. A machine for winding a coil on a magnetic core comprising means forsupporting said core,

a frame having guide means, slides guided by I said guide means, rollersrevolubly supported from said slides, each of said slides being providedwith rack means, a common pinion meshing with .all of said rack meansfor causing simultaneous motion of said rollers inwardly or outwardlywith reference to said core,rpower means for driving one of saidrollers, spring means actin on said pinion for urging said rollersinwardly towards the coil whereby said rollers are normally spring heldin direct contact with said coil, and manual means for rotating saidPinion in opposition to said spring means to move said rollers radiallyoutwardly away from the coil.

7. A machine for winding a conducting coil on a magnetic core comprisingmeans for supporting 1 said core, and means for directly engaging theportions or the coil at the same angular velocity,

and means for driving said roller means to rotate the coil, said meansfor supporting the-core being located wholly outsideoi the coil.

9. A machine for winding a. conducting coil assembly on a magnetic corecomprising means for 4. A machine for winding a coil on a magnetic corecomprising a plurality of spaced rollers arranged Ior rotary andtranslatory motion, means for imparting rotary motion to one of saidrollers, means operatively connecting said rollers for causingsimultaneous radial'motion of said rollers outwardly from said core assaid coil is built up during winding, spring means for holding saidrollers in direct engagement with said coil, and manual means for movingsaid rollers radially outwardly in opposition to said spring means.

5. A machine for winding a coil on a magnetic core comprising means forsupporting said core, a frame having guide means, slides guided by saidguide means, rollers revolubly supported from said slides, each of saidslides being provided with and power means for supporting said core, a.plurality of spaced rollers arranged to directly engage the coilassembly while it is being wound, means for causing simultaneous andequal motion of translation of all of said rollers as said coil buildsup to thereby maintain the coil assembly out of contact with said coreand centered with reference to said core, driving One of said rollers.

ROLLAND D. NELSON.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Vance July 15, 1941

